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AUGUST - OCTOBER 2017 Vol. 5 • No. 3

World class

lab equipment

Cocoa makes

creations come to life Dairy processing equipment’s bright future

A debut in film packing technology


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Delicious!

TURN KEY PROJECTS FOR THE BAKERY INDUSTRY

SHEETED BREAD LINES CAKE & PIE LINES WAFFLE LINES PIZZA LINES PASTRY LINES

WWW.TROMPGROUP.NL Texmate Bakery Solutions • 185 Beyers Naude Drive, 2195 Northcliff, South Africa • info@texmate.co.za • Tel. 031 764 03 53 • Tel. 011 888 86 67


CONTENTS AUGUST - OCTOBER 2017 Vol. 5 • No. 3

08 NEWS

Vanilla farming gets a big business boost Fruit producers target global trade Increased weighing accuracy ABB opens new Namibian office

12

BAKERY

R350 million investment for Albany A world of colourful topping and fillings Ishida assures triple production for Oropan Reduce costs with automatic tin spraying

17

INGREDIENTS

Cocoa gets the flavour just right A full house of ingredients

PAGE

10 “Labotec brings with it the best quality equipment to empower laboratories and manufacturers to make more accurate diagnostic decisions”

20 Beverages

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20

BEVERAGES

Sterilisation technology reduces environmental impact OneStep solution drives profits A new era in dairy-free drinks Is it the end of biofilm?

26

PACKAGING

Sidel enters Ghana’s beverage market Behn + Bates launches CareLine Technology PMD grows its African footprint

23

“A new label-friendly stabiliser supports the natural, healthy image of plant-based beverages.”

26 Packaging “Twellium took its first steps in Ghana’s beverage market with a PET line from Sidel”

DID YOU KNOW? PAGE

17

Cocoa is defined by colour and flavour.

ADVERTISERS’ INDEX Berndorf Band............................................. 7.................www.berndorfband-group.com CJP Chemicals.............................................. 16...............www.cjpchemicals.co.za Crest Chemicals........................................... 18...............www.crestchem.co.za GEA Africa...................................................... 25...............www.gea.com Hulamin Containers................................... 13...............www.hulamincontainers.co.za Ice Cold Bodies............................................ 5.................www.icecoldbodies.co.za Ishida.............................................................. 27...............www.ishidaeurope.com Krones............................................................ 23...............www.krones.com Labotec.......................................................... OFC...........www.labotec.co.za Omron............................................................ 26..............www.industrial.omron.co.za PMD Packaging Systems........................... 30..............www.pmdpackaging.co.za

Polyoak Packaging...................................... 29...............www.polyoakpackaging.co.za Porex............................................................... IBC.............www.porex.co.za Protea Chemicals........................................ 19...............www.proteachemicals.co.za Savannah Fine Chemicals........................ 17...............sfc-info@savannah.co.za Serac............................................................... 20..............www.serac-group.com Sidel................................................................ 21...............www.sidel.com/supercombi Specialised Exhibitions............................. 8.................www.propakcape.co.za Tongaat Hulett Sugar................................. OBC...........www.hulettssugar.co.za Tromp Group................................................ IFC.............www.trompgroup.nl Unique Flavors............................................. 15, 24........www.frutarom.com Vivit Foods.................................................... 14...............www.vivit.co.za

2017 Quarter 3 | Food Manufacturing Africa

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PAGE STRAP EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmediapub.co.za Assistant Editor: Aarifah Nosarka +27 (0) 11 877 6209 aarifah.nosarka@newmediapub.co.za Layout & Design: Kirsty Thomas +27 (0)11 877 6168 kirsty.thomas@newmediapub.co.za Contributors Penny Ntuli ADVERTISING

NOW IS THE TIME

for big processing and analytics

T

HE MANUFACTURING LANDSCAPE on the African continent is continually evolving. The ability to adapt to new requirements, whether governmental or consumer driven, has never been greater. In the fast-paced environment of quality laboratory and testing equipment, in-house testing and validation is critical. As food, beverage and packaging companies increase their investment on the continent, the need to work with an equipment supplier who understands their unique needs becomes greater. Labotec partners with some of the world’s leading brands. The company brings with it quality equipment to empower laboratories and manufacturers to make accurate, diagnostic decisions. Read all about what this South African-based supplier can offer on page 10. Albany Bakeries has revealed its R350 million investment in its facility in Bellville, South Africa (page 12). The state-of-the-art plant features high speed efficiency and a reduced carbon footprint. Find out how forward thinking management has increased production output from 6 000 to 12 000 loaves per hour, while reducing 3 964ℓ of water on total usage. We also investigate tailored solutions in toppings and filling on page 14. These products offer ample opportunities to unleash your creativity and companies can charge a premium for products with that special touch! Cocoa bean characteristics are extremely important to consider when formulating new products. On page 17 we take you through some of cocoa’s most salient colour and flavour features and debunk the alkalisation process and its impact on leavening in baked goods. A dairy processor in North Africa has reduced its energy consumption by up to 40 per cent, reducing environmental footprint while doubling capacity. It has also reduced processing losses by as much as one-third and generated a return on its investment in just two years. Cue to OneStep dairy aseptic processing technology. The system eliminates storage steps, reduces product losses and maintains consistent product quality. Find out more by turning to page 22. We end this edition by celebrating PMD Packaging Systems’ 50-year milestone (page 30). The company started by designing and building fully automatic bagging systems in Africa. Known for its Sigma range of vertical, form fill and seal machines, the company caters to a wide range of applications for the packing of food products. Africa is on a growth curve. Local and international companies are at the forefront of bringing innovation to food and beverage formulators. Don’t miss out on the opportunity to highlight your product in the next edition of Food Manufacturing Africa by contacting me on maryke.foulds@newmediapub.co.za.

Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com

Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmediapub.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmediapub.co.za Production Manager: Rae Morrison Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 713 9024 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR: Aileen Lamb CHIEF EXECUTIVE OFFICER: Bridget McCarney EXECUTIVE DIRECTOR: John Psillos NON-EXECUTIVE DIRECTOR: Irna van Zyl HEAD OFFICE New Media House, 19 Bree Street, Cape Town 8001 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 Email: newmedia@newmediapub.co.za

Happy reading,

Postal address PO Box 440, Green Point, Cape Town 8051

To advertise in Anita Raath

Sales executive +27 (0)82 976 6541

Candida Giambo-Kruger Sales executive +27 (0)71 438 1918

Carla Melless

Sales executive +27 (0)83 260 6060

Food Manufacturing Africa is published by New Media Publishing (Pty) Ltd quarterly and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost. Food Manufacturing Africa is printed and bound by CTP Printers - Cape Town. Copyright: all rights reserved. ISSN 2309-5334

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Food Manufacturing Africa | 2017 Quarter 2

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2017 DIARY

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od Moscow 11 – 14 WorldFo a ssi Ru w, sco Mo .ru www.world-food 11 – 15 drinktec y Munich, German m www.drinktec.co West Africa 19 – 21 Propak Lagos, Nigeria africa.com www.propakwest

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Food Manufacturing Africa | 2017 Quarter 3

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NEWS

Danone and Mars pledge support for Madagascan vanilla farmers A PROJECT FUNDED by Mars and Danone will help smallholder farmers in Madagascar restore vanilla quality, while reducing poverty. The Livelihoods Fund for Family Farming aims to triple farmers’ revenues and provide companies with fully traceable vanilla over the next ten years. Vanilla prices are highly volatile and extreme weather events are decimating crops. The project, which is also funded by Veolia and Firmenich, consists of an innovative model where

farmers and industry players share benefits and risks. Working with 3 000 family farms, the initiative aims to improve production and food security for farmers. Fanamby, a Madagascan NGO with extensive experience working with vanilla producers, will implement the project. Farmers will be trained over five years on sustainable practices to increase vanilla productivity and quality through agroforestry techniques. A new farmer-

Frutarom’s

ambitious acquisition targets FLAVOURS AND INGREDIENTS company, Frutarom, has shortlisted 200 acquisition targets, among them a total of 1 200 small and medium-sized businesses, including 800 in flavours and 400 in natural ingredients. The company aims to grow sales from US$1.15 billion in 2016 to US$2 billion by 2020. Frutarom is one of the food and beverage industry’s most acquisitive players, with eight acquisitions agreed this year and US$255 million in mergers and acquisition activity during 2016. Frutarom president Ori Yehudai is confident that Frutarom will meet the target it had set itself, and potentially exceed it. ‘To achieve this, we need to grow internally by four or five per cent,’ he explains. ‘In the last two years, we grew much faster – especially in the first quarter. We had to acquire revenue of around US$140 to US$150 million a year. In the last two years, we acquired an average of US$240 million, so we feel very confident we can achieve this target, maybe even before 2020.’

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Food Manufacturing Africa | 2017 Quarter 3

owned cooperative, structured with Fanamby’s support, will seek to connect producers directly to markets. It will collect the vanilla, cure and export it to the project partners. Through this work, it is estimated that around 60 per cent of the cured vanilla’s value will go back to farmers (instead of the current five to 20 per cent). Danone, Firmenich and Mars have pledged to purchase significant volumes of vanilla for their own products and brands.

A 10-HEAD WATERPROOF, midrange model, multihead weigher from Ishida has played a central role in assisting Leo Dunne, an Irish vegetable grower, to expand its supply of processed carrots. While oversized or irregular carrots are not suitable for the prepared carrot market, they are still high quality products. The company has realised these carrots can be successfully marketed through further processing, which is why it required an effective processing and packing line. The Ishida technology with three litre hoppers not only delivers reliability, but also achieves around 55ppm on 500g bags of carrots with an overall accuracy rate of 98 per cent. The machine’s ease of operation, including fast start-up using the simple-to-use remote control unit, gives it the flexibility to cope with the varying production demands of Leo Dunne. ‘All our staff are fond of the machine’s ease of operation. It is far more intuitive than other weighers. If there are any minor issues during production, the machine will identify them and inform the operator how to fix them. This is vital to maintaining production,’ explains Emmet Dunne, manager at Leo Dunne.

Weigher increases productivity

The multihead weigher at Leo Dunne


NEWS

African fruit producers and exporters create Afruibana

THE ASSOCIATION OF fruit producers and exporters from Cameroon, the Ivory Coast and Ghana was officially launched in Brussels during a visit by Cameroon Trade Minister, Luc Magloire Mbarga Atangana. The minister was lauded for this initiative, which will allow fruit producers on the continent to combine their efforts with a view to having their voices heard in international trade. Afruibana is an association established under Cameroonian law and gathers several representatives of producers and exporters from different sub-Saharan countries, notably Assobacam, the Cameroon banana industry association, and OBAMCI, an Ivory Coast organisation of producers and exporters of bananas, pineapples, mangoes and other fruits. The organisation is an open platform “Afruibana has with a mission to defend the interests of African fruit farming. thus become In Brussels, Afruibana has thus the permanent become the permanent representative representative of of a community of fruit producers and exporters across Cameroon, the Ivory a community of Coast and Ghana. The association fruit producers and will thus take steps to support exporters across competitiveness and export fruits to EU countries. It will also serve as an Cameroon” interface between producers in the sector and European institutions to secure financing and support for African fruit growers. ‘The European Union is the main outlet for African bananas, for historical and geographical reasons,’ says Joseph Owona Kono, chairman of Afruibana. In the Ivory Coast and Cameroon, the agricultural sector makes up approximately 60 per cent of the economy. Farming is one of the main sources of jobs and income for most of the rural population. For this reason, Afruibana has an essential role in reinforcing our ties with European agencies, favouring trade between Africa and Europe, and promoting socioeconomic development and contributing in the fight against migration.

Stop deforestation in Africa MONDEL Z INTERNATIONAL WILL begin working with governments in West Africa to minimise deforestation in its supply chain. The owner of Cadbury and Oreo has signed a memorandum of understanding with Côte d’Ivoire’s Ministry of Environment through its Cocoa Life sustainability programme. It has also signed a letter of intent with the Forestry Commission of Ghana and the UN Development Programme to reduce the effects of deforestation in the country. The commitments form part of Mondel z’s effort to completely eradicate deforestation and forest degradation from the cocoa supply chain. ‘Cocoa farmers and community leaders in West Africa tell us climate change is already impacting their farms,’ says Chris McGrath, chief wellbeing, sustainability and public affairs officer for Mondel z International. ‘With our investment in Cocoa Life, we have the capacity and the partnerships to help farmers become more resilient by adopting climate-smart solutions and protecting forests. These new agreements will amplify our existing work to protect the precious environment in cocoa-growing regions.’ The Cocoa Life programme and Côte d’Ivoire’s Ministry of Environment will map areas at risk of deforestation, and identify opportunities to restore forest cover in the Nawa region in the southwest of the country.

ABB opens new office in Namibia THE COMPANY ENTRENCHED its commitment in Southern Africa by opening a new 2 200m2 facility in Windhoek, Namibia. This move will increase the company’s capacity to supply, maintain and service products to the local market and neighbouring countries such as Zambia and Angola. The expanded facility will start servicing the market needs for medium voltage products, low and high voltage switchgear, and is soon to introduce distribution transformers into the local market. The new facility is a consolidation of the two offices ABB previously had in Windhoek. The company has realigned its organisational structure, to reflect its growth focus and position ABB Ability, which represents its complete portfolio of digital solutions. with a set of common enabling technologies that are used to build devices, systems, and applications. ‘Namibia is an important market for ABB, as it is the second largest contributor in the region to our revenue after South Africa. We have been in the country since the early 1990s, and this investment is part of our commitment to the region to enable the offering of more services and products,’ says ABB Southern Africa MD, Leon Viljoen. ‘The new facility will also help us to better service the neighbouring markets of Angola and Zambia from here, further improving our penetration into those countries.’ ABB has been operating in Namibia since 1990, after acquiring a small local contracting business and converting it into a full service business focusing on the local mining, utilities and industrial sectors. In the past decade, ABB’s operations in the country have grown parallel to the country’s GDP growth, resulting in more business from the public sector. Viljoen says the new Windhoek facility will also ensure that the company is prepared for anticipated continued public capital spend in the next few years. With a reasonable operation in Zambia, but very small in Angola, Viljoen envisions Namibia becoming the main centre for delivering services across the border in Angola. ‘One advantage for our team in Namibia is that they can speedily service customers in Angola,’ he enthuses.

2017 Quarter 3 | Food Manufacturing Africa

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COMPANY FOCUS The KjelMaster K-375

Analysis for a

GROWING AFRICAN MARKET Established in 1960 as one of the first laboratory supply companies in South Africa, Labotec partners with some of the world’s leading brands. The company brings with it the best quality equipment to empower laboratories and manufacturers to make more accurate diagnostic decisions. Labotec is instrumental in advancing research methods, results and improving production performance in diverse fields such as food and beverage, microbiology and chemistry amongst others. By Maryke Foulds DID YOU KNOW? Labotec’s export division was initiated six years ago in response to the demands of a growing African market. This division conforms to the special needs, on the sales and service support side, of the continent.

The Buchi NIROnline system

L

ABOTEC TECHNICAL SUPPORT offers after-sales service on all products to ensure that clients receive true value from their investment to operate efficiently and economically. The company recently launched a range of new products, ideal for the unique conditions presented by the African continent.

ROTAVAPOR PLATFORM SOLUTION Buchi Labortechnik is a leader in the development and supply of rotary evaporation equipment. The company introduced a groundbreaking commercial laboratory system with the launch of the Rotavapor R-300. This innovative, modular platform, features a plug and play concept. It enables seamless combinations of components to provide tailor-made solutions: from a basic rotary evaporator to a fully automated system. Globally, customers are expressing their desire to configure a rotary evaporator with their unique requirements in mind. The Rotavapor-R300 was designed as a modular system to accommodate that need. It offers maximum flexibility with options for central interface, heating bath, glass assembly, pump and chiller. A new level of unattended operation will be achieved with integration of an optional central interface. In conjunction with a Buchi vacuum pump and recirculation chiller, the perfect synchorinisation of process parameters, such as rotation speed, pressure and temperature (i.e. heating, cooling and vapour) open new possibilities.

Features include:

WITH LABOTEC YOU…

Save on maintenance costs

Eliminate breakdowns

Reduce downtime

Have peace of mind

• Automation of standard operation procedures (SOPs) using configurable methods • Unattended distillation of foaming samples • Remote process monitoring with push notifications to mobile devices • The Buchi Rotavapor Configurator app is available to simplify the process of selecting the optimal configuration for any customer’s needs.

NIR-ONLINE PROCESS ANALYSER It is critical to correct deviations occurring in any manufacturing process. This system offers

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Food Manufacturing Africa | 2017 Quarter 3


COMPANY FOCUS Elga Chorus water purification systems

Kjeldahl determination using the Buchi K-360 Distillation unit and Buchi B-400 mixer

SERVICE AGREEMENT ON NEW EQUIPMENT THE CUSTOMER SUPPORT programme is designed to help protect the value of investments by maximising the useable life of the equipment. The company offers service level agreements on a wide range of new equipment. The agreement includes full comprehensive servicing and repairs, including spare parts for up to two years. Customers are assured of priority scheduling, faster response, and access to experts available within its regional, national and global network. Free end-user training is given on all equipment sold by Labotec as required. Technicians provide the training on the operation of the equipment, while the product managers can provide application training.

real time process control. It closely monitors key parameters such as moisture, fat or proteins. The Buchi NIR-Online system analysers continuously provide accurate measurements within seconds to guarantee maximum production efficiency. The system is easy to use, and features a direct display of key parameters in the existing process control system. It is fully automated. Reports for auditing functions are generated and a calibration function ensures effortless method optimisation. The system can also collect reference samples through an optional bypass sampler. Units generally offer a payback period of less than one year, and immediate process corrections minimise waste and rework. It also optimises key parameters for maximum profit margins and offers a patented auto calibration function. This eliminates the need to develop extensive in-house calibration or the purchase of calibration data bases.

FAST FACT EQUIPMENT SOLD BY Labotec offers installation by trained and qualified technicians. They are sent overseas to the manufacturer for technical training.

A BROAD RANGE OF TECHNICAL SUPPORT

Extensive process expertise • Straight forward integration to process control systems • Ingress protected (IP65, IP66k) and ATEX certified (gas and dust) • Turn-key solutions for demanding measuring points such as discontinuous product flows in bucket elevators • Reliable results thanks to temperature controlled sensor.

NITROGEN AND PROTEIN TESTING Buchi is the supplier of the two most used key technologies for nitrogen

and protein determination – Kjeldahl and NIR. All requirements, including quality control for declaration purposes, inspection of incoming or outgoing goods, at-line production control, the new Master series, featuring KjelMaster K-375 and NIRMaster Pro IP65. There are many different factors to consider in modern protein determination in food and feed: consistence and variation of the sample matrix; random access versus batch processing; compliance with internal or official regulations; and versatile use for different analyses. Buchi is the reliable partner that masters all the complementary technologies at the highest quality level, combined with efficient and personalised service.

Award winning Buchi Rotavapor R-300

Labotec Technical Support offers a broad repair and maintenance programme, personal technical support, and a selection of service level/maintenance contracts. As the recognised national accredited service agents for international manufacturers, users are also guaranteed original spare parts. ‘With our people, products and services, we hope to perform to the total satisfaction of our clients. We want to ensure that you are empowered to make more accurate diagnostic decisions, advance your research methods and results, and improve production performance,’ enthuses marketing manager Debbie Shaw. ‘The ability to repair, maintain and calibrate laboratory instrumentation that we supply is an important aspect of our overall customer service policy.’ •

Labotec – www.labotec.co.za

2017 Quarter 3 | Food Manufacturing Africa

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BAKERY

High speed efficiencies reduce carbon footprint

A

LBANY BAKERIES HAS announced a R350 million investment into a new bakery in Bellville, Cape Town, South Africa. The project will include the building of a brand new plant with new technology equipment that reduces carbon footprint, and the upgrade of interiors of the existing plant. Albany Bakeries in Bellville was established in 1970 as a venture between Tiger Oats and National Milling. The new building occupies 6 884m2 compared to an area of 3 766m2 in the old bakery. The total yard size is 16 190m2 and includes new roads for delivery and commercial vehicles. ‘For the upgrade, we took the environment into account. We increased emissions efficiency by reducing the factory’s energy consumption, and placed emphasis on improving safety measures,’ says managing director Matshela Seshibe. Two Tweedy mixers, backed by British technology, will increase output capacity from 6 000 loaves per hour to 12 000. Willem Marais, Albany Bakeries’ supply chain executive explains, ‘With measured proportions of flour, water and yeast, the machine turns 300kg of bread dough per batch in six-minute cycles. This facilitates 10 mixing cycles per hour and illustrates the efficiency of the high speed Tweedy mixers. The new bread coolers and ovens are more energy efficient and perfect the baking process. Our revamped high-tech bagging system is another aspect that adds to the overall efficiency. We are also very proud of our safety record and the low incident rate this year.’ In 2015 the safety record was 1.25 lost time injury frequency rates (LTIFR); in 2016 0.56 LTIFR, and in 2017 until June Albany recorded 0.14 LTIFR. The improved safety measures include South African National Standards-approved walkways installed to eliminate unsafe crossing of conveyors.

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Food Manufacturing Africa | 2017 Quarter 3

Albany Bakeries (Albany) launched a R350 million new bakery with high speed efficiency and reduced carbon footprint.

DID YOU KNOW? The new plant has resulted in water savings of 3 964ℓ. It uses a total of 11 877ℓ, compared to the 15 841ℓ previously consumed.

Ribbon cutting ceremony during the day

Matshela Seshibe

Isolators are installed at all conveyors, and electrical panels to ensure lockout procedures are adhered to. ‘We have optimised the use of natural light with a raised roof to create an ergonomically friendly environment,’ Marais notes. ‘In addition, there is a water drenching system installed at coolers to prevent fire damage. Fire detection monitors are installed at key points around the plant. We aim to improve our carbon footprint with new energy efficient lights, motors and ovens,’ Marais points out. Regarding water consumption, the new plant saves 3 964ℓ, a total usage of 11 877ℓ compared to the 15 841ℓ previously consumed. Waste water is recycled and used to wash the trucks. ‘It is our vision to become the best baked goods company in the Western Cape; best in quality and taste, best in service, best in technology, with the best team to do the job. We have improved our recipe based on recommendations from consumer tests and have enhanced the taste profile of our breads,’ Shesibe enthuses. Albany is an award winning brand in the bread category in South Africa and has several accolades under its belt. These include the 2016/2017 TGI SA’s Kasi Star Brands; 2017/2018 Icon Brand Awards and the Sunday Times Top Brands Awards. The bakery operates 24 hours, seven days a week and trucks leave the yard from 3am to 6am. The bakery services 5 000 outlets in its coverage area from large supermarket chains to independent retailers and spaza shops. Seshibe concludes, ‘We are leaders in the baked goods sector and are confident that the Bellville upgrade with high quality equipment, energy efficient processes and tighter safety measures, will set the benchmark for all other bakeries in South Africa.’ •


BAKERY

Tailored solutions for quality applications Toppings and fillings are the most colourful and delicious way to add interest, flavour and mouthfeel to baked goods - enhancing value to potential customers. South African-based Vivit Foods supplies quality fruit preparations, syrups, sauces, jams and confectionery products to the food and beverage, bakery and dairy industries.

T

HE COMPANY PRIDES itself on the manufacture of customised products that offer clients value-added solutions and reliable ontime deliveries. All products are available to the South African market and for export into the continent. In 2004, Thinus Grobbelaar acquired the business and changed its strategic focus to the manufacture of high quality products for use in the food and beverage industry. The company’s focus shifted to the development of customer focused solutions. These processes are complemented by purchasing superior quality

fruit, flavours and other ingredients. ‘We want to understand our Products with natural customers’ needs. With flavours and colours with no added preservatives are also our experience in fruit available. Vivit Foods offers preparations we help to various packing sized to meet the customer’s needs. Products create innovative solutions are packed aseptically for them. Our clients benefit from into bags and then into buckets and/or boxes. more than 30 years’ experience within the food and beverage, bakery and dairy industries,’ Grobbelaar explains. The range of fruit pie-filling and toppings are bake- and freeze-thaw stable on request and can be used for cheesecakes, cupcakes, cakes, muffins, fruit pies, flans, jam tarts, doughnuts, Danish pastries and many other desserts. Flavours include strawberry, Black Forest, black cherry, red cherry, blueberry, kiwi, pineapple, apple and cinnamon, raspberry, mango, granadilla and mixed berry amongst others. Fruit content is adjusted to customer requirements. Other products in the portfolio include fruit pulp and preparations for yoghurt, drinking yoghurt and smoothies in a variety of different flavours. Vivit Foods manufactures egg-less lemon curd, caramel treats and spread in five kilogram packaging and other packaging options. Syrups for milkshakes, drinking yoghurt, smoothies, ice coolers and slushes can be packed. Jams in 25kg bulk packaging have been developed for bake-stable and spreadable applications. Salad dressings, mayonnaise and savoury gourmet sauces are also available. ‘Whatever topping or filling is used, be generous and have fun adding colour, flavour and that little extra that will place your products ahead of the competition. The astounding array of options in toppings and fillings for food and beverage products provide ample opportunity for bakeries and dairies to unleash their creativity and charge a premium for products with special touches inside and on top,’ Grobbelaar concludes. •

DID YOU KNOW?

VIVIT FOODS IS: • FSSC22000 certified • A SADC registered exporter • Halaal and Kosher certified • Woolworths and PnP approved suppliers. Vivit - www.vivit.co.za

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Food Manufacturing Africa | 2017 Quarter 3


BAKERY

A market for world-bread

T

HE SPEED AND accuracy of an Ishida multihead weigher has helped a leading Italian bakery reach a global market. The 14-head model with five litre hoppers has enabled the bakery to triple production of its range of small breads and rolls. It also increased efficiency rates on the packing line by five per cent and reducing rejects due to under- or overweight packs by 20 per cent. The new range of 11 different specialist small breads, including Ciabatta, Rosette, Tartarughe, Kaiser and Filoncini Integrali, are packed into bags, which are sold fresh locally and frozen for export, and into thermoformed trays for part-baked items. The Ishida weigher incorporates a diverting timing hopper that can feed the bagmaker and the thermoformer. For gentle handling of the product, which avoids any damage to the rolls or excessive crumbing, the weigher features bancollan inserts in the hoppers and a bancollan lining in the discharge chute. In

The system handles different bread varieties

addition, the discharge chute is divided into six sections to help direct the breads into the timing hopper, while a ring gate helps to break their fall. The Ishida system handles around 2 200 packs every hour. This is well within its capabilities and provides Oropan with the capacity for further growth in the future.

The line also includes an Ishida DACS checkweigher for final weight checks. This features lockable and liftable castor wheels to enable it to be moved between the bagging and thermocforming lines as required. Prior to the installation of the new line, bags were filled using a counting machine and the thermoforming trays by hand. The accuracy of the Ishida weigher has delivered a major benefit. As the individual piece weight of each bread roll can vary considerably, the counting method created a lot of weight variation. Thanks to the accuracy of the Ishida weigher, packs with a fixed and consistently accurate weight can be produced. The flexibility of the weigher has also enabled Oropan to widen its range of pack sizes – whereas the company previously packed the breads into just a 500g pack, it now also offers 300g and 400g bags. •

Ishida – www.ishida.com

Magical ingredients for

health AND wellness solutions We supply top quality, innovative, science-based health ingredients for the dietary supplement and functional food markets, addressing the growing demand for health and wellness products.

www.frutarom.com

2017 Quarter 3 | Food Manufacturing Africa

15


BAKERY

Automatic tin spraying system

packs a punch

Tectra Automation recently designed and supplied the Tectra 650 automatic tin spraying system for Bakesure Ingredient Suppliers. After a tenuous search for an automation supplier that could fulfil its requirements, the company turned to Tectra Automation as the only company that could supply all components for the system, including its unique Bosch Rexroth Variable Speed Drive (VSD) with specialised sequencing specifications.

B

AKESURE REQUIRED AN automatic tin spraying system for its baking plant in Johannesburg. The Tectra 650 is a stationed system that sprays 650 of the company’s baking trays per hour with its new cake-lease spray releasing agent, as the manual application process was costing the company valuable time. Tectra Automation, with its sole distributorship of Bosch Rexroth in southern Africa, designed and supplied the unique Tectra 650 system in just six months. The supplied solution included all components including: frames, Bosch Rexroth VSD, DC motor, control panel and the actual spraying equipment. ‘All the components work towards a common goal: the easy and quick application of cake-releasing agent on

Too much sugar in the cake?

the baking trays,’ comments Joseph Ngungu, mechatronics technician, Tectra Automation. The motor rotates the tin while the timers measure and monitor the number of tin rotations. After this, the actual spraying starts. Each tin is sprayed for one second when the machine automatically stops. ‘Thanks to the logic relays deployed in this system, this whole process is activated, stopped and controlled by a single push of a button,’ Ngungu adds. Tectra Automation opted for the adaptable Bosch Rexroth VSD as it is one of the only drives on the market that can be seamlessly integrated with a non-Bosch Rexroth DC motor, in addition to its logic relays and timers. ‘The drive’s adaptability and ease of use is well-suited to the fast pace of the bakery. When it is set with the right parameters, it will ensure the fast and simple spraying of the releasing agent after every bake,’ Ngungu concludes. The Tectra 650 automatic tin spraying system was delivered to Bakesure’s Johannesburg-based factory in May 2017. •

“The Tectra 650 is a stationed system that sprays 650 of the company’s baking trays per hour with its new cake-lease spray releasing agent”

Tectra 650 saves Bakesure valuable time by automatically spraying 650 baking trays per hour with cake-releasing agent

Use calcium to bake! Replacing 35% of icing sugar with Omya Calcipur® enhanches whiteness and reduces the calorific value by 136 kcal/100 g. Proudly represented by CJP Chemicals

www.cjpchemicals.co.za 011 494 6700

16

FunctionalFunctional minerals and beyond... minerals and beyond... Functional minerals and beyond... www.omya.com/fpc www.omya.com/fpc www.omya.com/fpc

Food Manufacturing Africa | 2017 Quarter 3

CJP Chemicals.indd 1

2017/08/15 10:32 AM

Hytec Group - www.hytecgroup.co.za


INGREDIENTS

The case for cocoa The characteristics of cocoa beans are extremely important to consider when formulating products in the food industry. Using them correctly will ensure the best outcome in applications such as baked products.

T

HE ORIGIN OF cocoa beans is the first important characteristic in getting the flavour right. Cocoa from West Africa is known for delivering a solid note, whereas beans from the Central Americas will deliver a more delicate, balanced and fruity nuance. Each origin powder comes with its own set of unique flavour and colour characteristics. Fermentation and drying plays an important role in flavour development. Roasting and alkalisation have the greatest impact, and require knowledge and experience to extract the full potential of the bean. Alkalisation is a process specific to cocoa. This step reduces acidity and increases the cocoa note. Alkalisation also helps to control colour. A non-alkalised cocoa is beige, whereas an alkalised powder can be steered to dark brown, reddish brown or black. Special care Cocoa is defined by colour must be paid to both parameters. and flavour. Overly strong alkalisation can get you the desired dark colour, but will increase the bitterness rather than the cocoa aroma. When used correctly, the palate of flavours and colours in cocoa powders

DID YOU KNOW?

that’s value-driven The finessence of cocoa

The Pow(der) of success

Exclusive distributor for Barry Callebaut cocoa

Johannesburg +27 11 856 4500 l Cape Town +27 21 551 5353 l Durban +27 31 202 0794 sfc-info@savannah.co.za

2017 Quarter 3 | Food Manufacturing Africa

17


INGREDIENTS

can be brought to life by bakers when creating indulgent products. In general, bakers will use medium to strong alkalised cocoa powders for their products. Dark brown to black cocoa powders for cookies or cake, make a bold cocoa-indulgent product. This is apparent with brownies and muffins, where the general perception is that the darker the product, the more chocolaty it will be. Another example is a devil’s food cake (dark reddish chocolate cake), which requires a red cocoa powder to get the reddish colour. Alkalisation allows cocoa experts to essentially play with powders to innovate new product concepts or take existing recipes to enhance or differentiate them. With this playful take on cocoa science, creations come to life. Cocoa powder can impact leavening in baked goods. Leavening requires an acid and/or heat to get started. In this reaction, the alkalinity of a cocoa powder plays a large role in the acidity of a recipe, and will alter the direction of the leavening reaction. With a natural powder, the impact is different compared to when a dark powder is used, which reflects in more or less leavening. This needs to be taken into consideration when perfecting recipes. Exchanging powders in a recipe, from medium alkalised to dark alkalised, will not only impact the flavour and colour, but also reduce the volume of a cake or the texture of a cookie if nothing else is done to compensate. This is another

example of how cocoa powder has a profound impact on the end product.

DEFATTED COCOA POWDER

“Alkalisation allows cocoa experts to essentially play with powders to innovate new product concepts”

Other popular bakery applications are Swiss rolls (sponge cake), meringues or macarons. These are extremely delicate recipes, in which fat is not desirable for the composition. The structure of these applications is established by the protein in eggs. Fat, when present, acts as a lubricant, which leads to a reduced structural integrity, and therefore, reducing volume of the dough. Defatted cocoa powder (with less than one per cent fat) is used to avoid yield loss. In identical recipes, where cocoa powder is changed from a high fat powder to a defatted cocoa powder, the differences are clear. Meringues or macarons made with a defatted powder have a more intense colour with a finishing gloss, holding their volume and structure. Besides those technical benefits, defatted cocoa can also be used in diet products, bringing a chocolate taste with minimal calories, which is required by these types of applications. By understanding the use of cocoa for bakery products, it is possible to work on recipes with a flexible approach without losing the flavour balance of your product. •

Savannah Fine Chemicals - sfc-info@savannah.co.za

In partnership with

Reformulate with the experts Lowering or even eliminationg sugar in your formulations isn’t easy. And meeting consumer expectations when it comes to texture and mouthfeel? Even tougher.

Crest Chemicals

CP Kelco offers a broad portfolio of hydrocolloids and the technical expertise you need when reformulating to meet your sugar reduction goals. Years of research and development have resulted in a comprehensive range of stabilizers and texturizers that can be customized to suit any reformulation challenge you’re up against. Let our technical experts work with you to conceptualize and reformulate your tasty, low-sugar foods and beverages. Contact us: Johannesburg (011) 254 3300 | Cape Town (021) 534 3140 | Durban (031) 902 5324 | East London (043) 726 8027 | Port Elizabeth (041) 453 1981

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Food Manufacturing Africa | 2017 Quarter 3


INGREDIENTS

More value, more choice O

MNIA’S CHEMICALS DIVISION, operating under the Protea Chemicals (Protea) brand, has a wealth of experience and a reputation for excellence in the distribution of specialty, functional effect chemicals and polymers in sub-Saharan Africa. Protea Chemicals Food and Beverage offers high-quality, fullservice warehousing and distribution to the market for food ingredients, More than just a chemical supplier chemicals, and blends. As a major player in both South Africa and the rest of the African continent, it to leverage the basket offering to local and this business unit adds value through international markets. cost-effective, reliable supply into the Key product lines include (but are not following sectors: limited to): food commodities, acids, • Beverage (alcoholic and non-alcoholic) preservatives, starches, sweeteners, dairy • Dairy ingredients, proteins, phosphates, gums, • Baking and confectionery stabilisers, emulsifiers, wine chemicals, and • Meat and Culinary. specialty food ingredients. Protea Chemicals Food Ingredients offers a ‘Our valued partnerships are key to our wide variety of quality products that enable customers’ success and our team of product

managers plays a critical role in ensuring that we bring superb quality products to the market,’ says industry manager Nicole Lombard. Protea Chemicals recognises that maintaining internationally benchmarked safety standards through safety, health, environment and quality (SHEQ) implementation is critically important to all stakeholders. The Dual Product Testing Policy is applied to all products sourced from emerging markets and is an example of the company’s commitment to the continuous supply of superior foodstuffs. Membership of the Omnia Group, ISO accreditation, and a SANAS-accredited laboratory offers customers a distinct advantage with regard to both quality and product assurance. A long-term growth strategy for this business unit includes partnering with key clients and suppliers to promote synergies and the responsible, sustainable sourcing of food products. •

Protea Chemicals www.proteachemicals.co.za

FOOD INGREDIENTS

2017 Quarter 3 | Food Manufacturing Africa

19


BEVERAGES

A bright future in sterilisation

Serac has confirmed its expertise in container treatment based on dry processes with an industrial sterilisation solution using ebeam technology.

T

HE SYSTEM IS capable of ensuring a five-log bacteriological reduction on Bacillus Pumilus without leaving any chemical residue in the container. It also eliminates the consumption of chemical agents to decontaminate bottles. BluStream is a real technological breakthrough in the aseptic filling of plastic bottles.

QUICK STERILISATION WITHOUT CHEMICAL PRODUCTS Unlike peracetic acid (PAA) and hydrogen peroxide (H₂O₂) treatments that rely on chemical principles, BluStream is based on a physical process. It uses an

Serac innovates and reduces environmental impact thanks to BluStream technology

issuer, which throws an electron beam over the container’s surface. Electrons quickly destroy micro-organisms by breaking their DNA chains. This enables BluStream to achieve a fivelog bacteriological reduction on Bacillus Pulumilus with a 1.5ℓ bottle in about five seconds. Without the use of chemicals, BluStream ensures that containers are totally free of any toxic residue. The simpler process makes sterilisation easier to monitor, as it relies on three critical easy to control parameters, namely voltage, current intensity and exposure time. BluStream treatment is also more economical in production as it requires no chemicals, no water, no compressed air, and a minimum increase in electrical consumption comparable to the H₂O₂ treatment.

FAST FACT BLUSTREAM IS PERFECT for manufacturers wishing to highlight: • Production processes that respect human beings and the environment • Brands that follow natural trends and target sensitive consumers.

CONTINUOUS AND COMPLETE STERILISATION IN A COMPACT UNIT

PRIMARY PACKAGING SOLUTIONS For your dairy product innovation

The Serac’s BluStream unit is more compact than PAA and H₂O₂ equipment. The floor area is only 20m² for a rate up to 36 000 bottles per hour. Bottles are treated on two successive carousels: the first one for the exterior treatment, and the second one for the interior treatment of the bottle, continuously, at rates up to 36 000 bottles per hour.

FOR ALL PRODUCTS PACKED IN PLASTIC BOTTLES BluStream treatment is compatible with all kinds of plastics; HDPE, PET, PP, PS, whatever their weight or shape (off handle). All bottle sizes can also be treated, provided that the neck diameter is above or equal to 30mm. Treatment efficiency allows this method to be used for high-acid products (fruit juices) as well as for low-acid products (cow milk, soy milk, other vegetable milks and all nutritional products). Serac offers with BluStream a cutting-edge sterilisation solution, which reinforces its position as an expert in the aseptic filling of bottles. Apart from the new machines, BluStream sterilisation will also be available on the modernisation of existing lines. • Table 1: Bluestream treatment time

Container

Discover us at www.dairy-packaging-machines.com www.serac-group.com

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Food Manufacturing Africa | 2017 Quarter 3

0,5L 1,0L 1,5L

Treatment time 2 sec. 3,5 sec. 5 sec.

Dose

25 kGy 25 kGy 25 kGy

Serac Group – www.serac.com


SuPer faST SuPer SmarT SuPer Combi

Take your WaTer and CSd PeT ProduCTion To greaTer PerformanCe levelS The new Sidel Super Combi is a smart, all-in-one system that delivers ready-to-sell products at very high speed, while ensuring maximum uptime and ease of operation. Integrated equipment intelligence means it continuously self-optimises to give you greater levels of performance and efficiency and an attractively low Total Cost of Ownership. find your smart solution at sidel.com/supercombi


BEVERAGES

HURRAY FOR

BIG DAIRY PROCESSING OneStep dairy aseptic processing technology eliminates storage steps, reduces product losses and maintains consistent product quality. It’s one of the biggest advances in processing technology in the past decade, writes Penny Ntuli.

T

HERE IS THE result in actual savings and reductions of water and energy consumption, for starters. Electricity consumption is cut by up to 31 per cent, steam by 78 per cent, and water (for cleaning) by a conservative 40 per cent. A South African dairy producer reduced its water consumption from three litres per litre of milk, to just 300ml per litre of processed milk. To put that in perspective, another processor collected more than 600 million litres of raw milk from producers in 2015. Old processing methods would have consumed as much as 1.8 billion litres of water, a figure that could be cut to just 180 million litres on modern equipment. That has a significant impact on a country’s natural resources let alone the means of powering it to its destination, the power consumed in using it, and the resultant effluent. A processor in North Africa has reduced energy consumption by up to 40 per cent, reducing its environmental footprint, yet doubling production capacity. It has also reduced processing losses by as much as one-third and generated a return on its investment in just two years. These savings are possible through harnessing OneStep technology, which Continuous single-stream blending with OneStep technology for recombined milk

“… the technology cuts annual running costs by an average of 30 per cent compared with more traditional methods”

eliminates traditional steps from the production process. The pasteurisation and intermediate storage steps of traditional long life milk processing are removed and replaced by one, continuous process. Automation rounds out the means of efficiency gains since it reduces milk waste traditionally accumulated between processing steps. It also improves quality and consistency. In-line blending eliminates the need for pasteurisers, and streamlined processing effectively eliminates the need for large storage tanks. Fewer, smaller tanks require less cleaning-in-place (CIP), less tank preparation, a smaller footprint, resulting in less maintenance. With fewer elements to the processing line to transform raw milk into hygienic, safe, affordable, packaged milk ready for safe transportation anywhere in the world, there’s less machinery to maintain, service, clean, and power. Overall, the technology cuts annual running costs by an average of 30 per cent compared with more traditional methods. The South African producer and processor mentioned utilising this technology, is cutting water consumption to one-tenth and produces half the effluent. This has reduced production time for further savings. The technology can be used to produce single products, or configured into multiple streams to produce several recipes - giving customers full production flexibility. This is particularly effective for modern producers looking to diversify

product offerings, with formulated and flavoured dairy products. It’s one thing to have a rapid and highly cost effective production process, but it must also be safe and ensure a good quality product. While formulated and flavoured liquid dairy products add value to brands, they can be challenging to ensure quality consistency across taste, stability and dissolving. The ability to enhance vitamin quantities or proteins without separation to make a healthy product even healthier is also critical. Producers can also prepare long life milk from powder in one continuous step that reduces operational costs by as much as 40 per cent and cuts carbon emissions in half. Producers mix skim milk powder with preheated water to create a concentrate that is blended with precise amounts of water and fat before being UHT-treated. It is common in the Middle East, Far East, and Africa, where there is insufficient supply of raw milk, to produce milk from powder. It is increasingly seen as a good source of protein. The market is expanding and competitive, resulting in price increases. Producers consequently search for innovative methods to reduce production costs. Coupled with a cloud-connected world of condition monitoring and data analysis for preventative maintenance means these technological innovations go beyond providing the safest, most hygienic dairy solutions on the market they can also cut machine failures before they occur to further reduce downtime and costs. •

PENNY NTULI is

communications director at Tetra Pak South Africa. Tetra Pak – www.tetrapak.com

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Food Manufacturing Africa | 2017 Quarter 3


BEVERAGES

Increase the appeal of

dairy-free drinks A

billion of those sales – a dominant position that is now being challenged by the rise of drinks based on rice, almond and oats. Grindsted Gellan MAS 100 provides reliable stabilising functionality with a low cost in use, regardless of raw material fluctuations. No other additives are required – supporting the consumer preference for cleanlabel, plant-based drinks that are free of artificial ingredients. •

NEW LABEL-FRIENDLY stabiliser Insights have registered an explosion in supports the natural, healthy sales of plant-based drinks. In 2016, sales in Limette, Food Manufacturing Africa, 136 billion. x 200 mm, CC-en46-AZ369 08/17 image of plant-based beverages. Western Europe alone reached US$1.5 Du Pont - www.dupont.com DuPont Nutrition & Health (DuPont) has Soy beverages accounted for around US$1 made it easier for beverage manufacturers to produce stable soy, almond and other plant-based drinks with a refreshing texture and a clean label. Utilising drinktec 2017 a new ingredient in the Munich, 11 – 15 September DuPont Danisco range, Hall B6 manufacturers can obtain all the functionality they need without mixing in other additives. The gelling ingredient is Grindsted Gellan MAS 100 – otherwise known as gellan gum. It is a label-friendly stabiliser for non-dairy beverages made with pulses, grains, nuts and plant-derived protein. Previously produced by DuPont for ingredient systems, it is now available as a single ingredient for the first time. ‘The main driver is the demand for dairy-free drinks for lactose-intolerant consumers. According to market intelligence, close to 25 per cent of European consumers are reducing or avoiding dairy products in their diet for health reasons,’ says Jean-Baptiste Dufeu, DuPont global product manager. ‘Our ingredient enables manufacturers to respond to this trend by stabilising particles in plantbased beverages and creating a refreshingly smooth texture. Consumers experience a refreshing drink with an authentic flavour profile.’ Market analysts at Euromonitor and Innova Market

Partner for Performance

We do more.

CC-en46-AZ369_0817.indd 1

07.08.17 11:18

2017 Quarter 3 | Food Manufacturing Africa

23


BEVERAGES

Say bye-bye to biofilm

G

EA IS SET to launch a range of curative and preventive treatment for enhanced quality and productivity for the global beverage and dairy industry. The new equipment will be unveiled at this year’s drinktec. The show will be held in Munich, Germany from 11 to 15 September. At the event, GEA Service will emphasise its Safexpert antibiofilm programme.

Biofilm in the production line is a constant source of product contamination and product loss. By eliminating biofilm, product contamination should not occur and product loss will be reduced. This should result in consistently high product quality. During the GEA Safexpert programme, equipment will be screened systematically and bacteriological species will be identified. Any biofilms will be removed to enhance the safety and quality of the products. Due to the consistent nominal production capacity, customers will have a high return on investment.

HIGHER SHELF LIFE, LESS CIP Since biofilm impacts product stability, GEA Safexpert should extend the shelf life of the products. Biofilm-free production also requires less CIP, thereby GEA will introduce a new treatment that does away with biofilm

Enriched UNLOCK A WORLD

WITH REFRESHING FLAVOURS

BEVERAGES: FLAVOUR SPECIALITIES Unique, high quality sweet and savoury flavours for food and beverage products • Natural botanical extracts

• Flavour specialities

• Essential oils

• Citrus specialities

• Beverage emulsions

• Clean label flavours

• Speciality aroma chemicals • Snack seasonings

www.frutarom.com

24

Food Manufacturing Africa | 2017 Quarter 3

extending production time per line and per day. The programme investigates the production equipment for biofilm, biofilm-forming bacteria and also the type of contaminating bacteria that usually develops from biofilm. These include Listeria monocytogenes, Salmonella, Bacillus cereus and Pseudomonas aeruginosa.

QUICK CONTAMINATION GEA investigates each line suspected of containing biofilm, according to an assessment. By using a special UV lamp for fast detection and next-generation ATP G2 analysis for verification, contaminated lines are identified in just a few hours. Affected lines are flushed with a patented enzymatic solution that cuts the biofilm open, followed by removal of the contaminating bacteria with a peracetic acid. This is also used as a sterilant. After treatment all systems are inspected for enzymatic residues. •

GEA – www.gea.com


GEA Service improves life cycle cost of your plant and equipment GEA Service offers full life cycle services to ensure your continued operation and success. Apart from beginning of life services (which includes

For more information on our extended lifetime

installation, commissioning and training), GEA Service

service offering, upgrades and factory rebuilts,

also offers lifetime corrective and preventative mainte-

contact Gert Scheepers at GEA Africa in Midrand at

nance together with spare parts.

011 392 7114 or gert.scheepers@gea.com.


PACKAGING

Bottling with a pop in Africa In 2013, Twellium took its first steps in Ghana’s beverage market with a PET line from Sidel. The company recently invested in two new complete lines, making it a major beverage player in the West African sub-region, with a total of five production lines, all supplied by Sidel. VARIETY REQUIRES FLEXIBILITY

T

WELLIUM BRINGS BEVERAGES, which have proven popular among European and American consumers, to the African region. Its formula for success has been a combination of its pure and natural mineral water with European technology and international standards in the manufacturing process, and meeting all the certification and safety standards of the Food and Drugs Authority in Ghana. The award-winning company produces a variety of drinks, including Verna Natural Mineral Water, Rasta Choco Malt, Dr. Malt and the Easy range of products. Other products such as Rush Energy Drink, American Cola, Planet and Bubble Up are all produced by Twellium as a franchise of Monarch Beverage Company, a global business headquartered in Atlanta, United States. Over the past few years, Sidel and Twellium have forged a close working relationship. This is based on continual improvement and cooperation. With more than 40 years’ experience in complete lines for carbonated soft drinks (CSD), Sidel has also worked on optimising the existing lines, providing energy saving solutions and maintenance support.

Beverage production and bottling line

Twellium had to increase production capacity to cater to the needs of the African market while further securing high flexibility. The company’s two chairmen, Hassan and Hussein Kesserwani state: ‘Flexibility is imperative for the company because of the variety of drinks we produce – from CSD to juice drinks with preservatives and the non-alcoholic malt drinks that are popular in the region. In Ghana, our recent investment in a Sidel Matrix PET complete line has fulfilled these needs by offering faster changeovers and the ability to handle many different bottle formats.’

CUTTING ENERGY COSTS WHILE EXPANDING DESIGN OPTIONS

“With the StarLite base, the company saves on raw materials and also on energy as the container can be blown using less air pressure”

A case in point of energy costs reduced is in the Sidel Matrix blower which consumes less compressed air and electrical power. This results in energy savings of up to 45 per cent. Additionally, the Eco Oven technology – patented by Sidel – can be used to upgrade existing blowers and cut energy costs because it uses fewer lamps for heating the preforms. This reduction in energy consumption was particularly welcome because Ghana has faced considerable rises in energy costs. Twellium adopted Sidel’s StarLite base design. This patented base enables bottle weight to be reduced by 20 per cent for 0.5ℓ bottles, while improving stability and protecting against stress damage during production and transport. •

Sidel – www.sidel.com Twellium – www.twelliumind.com

Your specialist automation partner As a partner in all your automation requirements we offer personal solutions, knowledge and expertise. Whether your automation requires a simple and economical solution, or your target is advanced, highspeed control, you can find what you need in Omron’s line-up of quality products and solutions. Omron Electronics ZA 011 579 2600 info.sa@eu.omron.com www.industrial.omron.co.za

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Food Manufacturing Africa | 2017 Quarter 3


Weighed and measured to the point of perfection

Precision shouldn’t come at the cost of speed. Our world leading weighing technology combines fast processing with unparalleled accuracy and reliability. It’s how you can reduce your product giveaway while increasing your efficiency. Work in harmony with Ishida.

ishidaeurope.com


PACKAGING

DID YOU KNOW? Immense special care is required when baby food or milk powders are filled into 10 to 25kg bags.

The Roto-Packer Adams has been designed for products that require extreme hygiene care during filling

The new technology seals PE film bags up to the outer edge

REVOLUTIONARY

film bag packing German packaging manufacturer, Behn + Bates delves into details on its new hygienic concept, the CareLine technology.

H

YGIENIC EXPERTS CONSIDER plastic bags to be the most hygienic packing material for highly sensitive food products such as baby food. The risk of contamination is reduced to an absolute minimum during the production of PE films. However, machines on the market have not been able to meet hygienic standards required. Identifying a gap in the market, Behn + Bates has concentrated exclusively on the food industry. With its years of expertise, the company developed an idea for a new hygienic machine specifically for PE film bag filling. For the first time in the company’s history, the entire process of machine development has been closely followed and accompanied by a key customer of Behn + Bates. The process has also been pursued by a PE film producer, which has developed a new optimised double layer gusseted film in parallel for better product protection. The new packing machine, the Roto-Packer Adams Care-Line edition was revealed in May.

28

THE ROTO-PACKER ADAMS’ SPECIALITY The machine components were combined in an innovative way to minimise dust deposit areas and guarantee optimum cleaning features. For example, the number of integrated components has been reduced to the bare minimum. All the machine’s parts are encased, and there are almost no additional parts above the open bag, like screws or nuts, which could fall into the product during filling. Its edges are inclined, whereas normal machine corners are rounded. There are no open threads, edges or drill holes in the sectional steel frame. Effectively, there are no points where product dust would usually build up. Owing to the inclined edges and rounded corners, product dust deposits can easily be removed.

CERTIFIED COMPONENTS During the development of the new machine, Behn + Bates specially focused on the selection of components. The European Hygienic Engineering & Design Group has

Food Manufacturing Africa | 2017 Quarter 3

certified the majority of the parts included in the hygienic machine. The novelty in the functioning of the technology is its PE film welding comprising perfect edge definition. This concept protects products in the filled bag from vermin, dirt, deteriorations and more. This form, fill and seal (FFS) system is ideal for filling powders into common PE film bags. It is suitable for filling double-layer PE film bags, which ensure better product protection. As in every known FFS machine, the bag is formed from an endless gusseted film, conclusively filled and sealed. The attention to detail, or in the case of Behn + Bates, the attention to hygiene can be noted from the PE film sealing. This technology has been developed to seal PE film bags up to the outer edge. The company says that with this technology, it is well prepared to meet the rising hygienic demands in the food industry and tread new paths with customers wanting to introduce trend-setting packaging concepts into their product catalogues. •

Behn + Bates – www.behnbates.com


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B t s a tand u it S Vis ape, C ak

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We speak dairy It may all come from the same place, but when it comes to the packaging there’s no one-size-fits-all. Our diverse range of award-winning dairy containers and aseptic carton systems is specially designed to fulfill your complex dairy processing needs. We know, because we speak your language. Let’s talk.


PACKAGING

50 years and still going strong T

HIS YEAR, PMD Packaging Systems (PMD) celebrates its 50th anniversary. The company started by designing and building fully automatic bagging systems in Africa. Michael Spencer, a representative of PMD, says the company’s name became ubiquitous in the world of packaging. ‘Today PMD is no longer the sole provider of bagging machines but after 50 years, it has become a leader in Africa in terms of state of the art packaging systems.’ The company is known for its Sigma range of vertical form, fill and seal machines, which cater to a range of applications for packing food products. Applications include dry granular and powder products, liquids and snacks. In addition PMD produces a fully automatic cartoning machine and a range of snack food equipment from extruders through to frying, flavouring and packing.

The Sigma 3 vertical form, fill and seal machine

The machines perform at high speeds of up to 100 bags per minute. They operate reliably and efficiently with LDPE, which is often required with rice, beans and sugar. The Sigma 6 machines are able to handle 10 and 12.5kg packs. Each machine can be equipped with various dosing systems, dependent on the customer’s requirements. The technologies can also include multihead weighing systems, auger screw filling for powders, volumetric cup dosers, bucket elevators and special purpose feeders. ‘The Sigma range of machines are especially favoured by end users that have tough demands, including 24/7 production,’ Spencer adds.

AFRICAN FOOTHOLD PMD has installed packaging machines at customers all over South Africa. A large percentage of sales is to customers in many African countries. All PMD installations are backed by a team offering technical support via telephone, e-mail and internet communication. ‘This extends to site visits by our experienced engineering personnel,’ Spencer concludes. •

PMD Packaging Systems – www.pmdpackaging.co.za

PMD HORIZONTAL CARTONER SIGMA 1 VFFS

1967 - 2017 Suppliers of Packaging and Processing Machinery www.pmdpackaging.co.za | Tel: +27 (0)11 795 1994

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Food Manufacturing Africa | 2017 Quarter 3


For all your sweetener needs...

The sweeteners are blended into working combinations to meet customer’s requirements. The range includes: • Acesulfame K • Aspartame • Cyclamate • Fructose (Crystalline & Liquid) • Isomalt • Neotame • Saccharin • Sucralose • Polydextrose • Xylitol • Erythritol • As well as a wide variety of sweetener blends For more info go to www.hulettssugar.co.za

Benefits: • A wide range of products • Long standing experience • National sales team, distribution network and technical services • Flexible pack sizes • Reliable, consistent quality • Products formulated to suit customers’ specific needs

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Cape Sweeteners, a Division of Tongaat Hulett Sugar South Africa Ltd, specialises in the development and manufacture of intense sweetener blends and bulking agents used in beverages, baking, confectionery, dairy and ice-cream manufacturing industries.

Food Manufacturing Africa Aug-Oct 2017  

The manufacturing landscape on the African continent is continually evolving. The ability to adapt to new requirements in the field of labor...